Safety Link X-Rail Quick start guide

INSTRUCTION: XRAIL-INST-SURFACE-MOUNT REVISION: 2.0
®
Innovative
Fall Protection
SafetyLink
Figure 1
x-Rail
InStallation and Use
Horizontal Rigid anchor line

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1 Warning
⚠ Improper Use, Installation or Maintenance may result in serious injury or death.
⚠ The building or structure for the anchorages should be assessed by an engineer to
ensure that the structure is adequate for X-Rail installation works.
⚠ SafetyLink's Height Safety Systems must only be installed as per our installation
guides, to structures as specified in the installation manual for each product.
⚠ All safety procedures must be complied with in accordance with the current safety
code(s) of practice(s) for working at heights in your region. Ensure safety at all times by
being attached to suitable anchor points and approved safety equipment or approved
scaffolding.
⚠ Installation is to be carried out by, or under the supervision of, a competent person.
⚠ A personal energy absorber or a fall-arrest device with a personal energy absorber
must be used in conjunction with all SafetyLink Anchorages and Lifeline systems.
⚠ Do not carry out any modifications on this system without written permission by
SafetyLink Pty Ltd.
2 Specification
2.1 Description
The SafetyLink X-Rail is a Rigid Anchor Line suitable for use as part of a personal fall protection
system. The X-Rail offers a horizontal Rigid Anchor Line with one or multiple Mobile Anchor
Points for attaching to.
2.2 Standard
The X-Rail Rigid Anchor Line System is compliant with AS/NZS 1891.2, EN795:2012 and PD
CEN/TS 16415:2013.
2.3 User Rating
The X-Rail Rigid Anchor Line is rated for up to 4 users per system and in any span.
2.4 Material Specification
COMPONENT DESCRIPTION
Rail Aluminium 6000 series
Cross Plates Aluminium 6000 series
Joins Aluminium 6000 series
Fasteners Stainless steel 316
End Cap Nylon 66
End Stop Aluminium 6000 series, Rubberised Nylon
Shuttle Aluminium 6000 series, Stainless steel 316, Nylon 66

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2.5 Components
Figure 2
RAIL LENGTH 3M CROSS PLATE RAIL JOIN KIT CONCEALED
XRAIL-TR-102-3M XRAIL-TR-210 XRAIL-TR-005
RAIL END CAP SHUTTLE STOP SHUTTLE
XRAIL-TR-213 XRAIL-TR-006 XRAIL-TR-014
90°CORNER 45°CORNER RAIL JOIN DOWEL
XRAIL-TR-104 XRAIL-TR-107 XRAIL-TR-212
RAIL SCREW DRILL ON-SITE FIXTURE RAIL DRILL BIT
XRAIL-TR-907(OTS) XRAIL-TR-402 XRAIL-TR-401

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3 Installation
3.1 System Design
3.1.1 General
Systems shall be designed to limit free fall, swing fall and maximise fall clearance. Where
possible, systems should be designed to prevent a free fall from occurring.
It is important to consider the location of corners when designing your system to ensure the
rails and corner fastening detail can match the detail in Section 4 of this instruction.
The X-Rail Rigid Anchor Line shall be installed on an angle no greater than 5º.
Figure 3
5˚

3.1.2 Structure Capacity
The supporting structure shall be capable of supporting 15kN in all direction that the system
can be loaded.
⚠ All load cases shall be considered by a trained engineer.
The structures in Figure 4 have been assessed by SafetyLink and are deemed to be acceptable.
⚠ If there is any doubt of the structures suitability, consult a trained engineer.
Figure 4
Type Size Spacing
Steel Purlin C or Z 150mm x
60mm x 1.5mm
Maximum purlin spacing 600mm or rail system to span
a minimum of 5 purlins.
Timber Rafter
and Batten
Rafter F7 or MGP
10 140mm x
45mm, Batten F7
or MGP 10 70mm
x 35mm
Maximum rafter spacing 600mm

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3.1.3 Intermediate Fixing Spacing
Exact intermediate fixing spacings are determined by the roof sheeting. The below are the
maximum allowable distances.
I On a straight section of rail designed for fall arrest, intermediate fixing shall be
installed at a distance not greater than 1m.
II On a straight section of rail designed for abseil, intermediate fixings shall be
installed at a distance not greater than 0.6m.
Figure 5
A
A
Across the Seam In-line with the Seam
A - 1000mm maximum for fall arrest
A - 600mm maximum for abseil
Figure 6
SPAN LENGTH MAXIMUM DEFLECTION (4 PERSONS)
600mm 50mm
1000mm 200mm
3.1.4 Structure Fixings
To prevent the below listed roof profiles from slipping or moving under load, 8mm Tri fold
aluminium rivet shall be installed in to the purlins along the entire length of the rail. One rivet
shall be installed in each pan of the sheeting, either above or below the rail. Rivets shall only
be installed for rails running across the seams of the roof sheet. See Figure 7.
I Klip-Lok 700
II Klip-Lok 700 Hi-Strength
III Klip-Lok 406

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Figure 7
3.2 Fixings
3.2.1 Rivets
All rivets used to connect the rail profile to the roof sheeting, rail profile to the Cross plate or
Cross plate to the roof sheeting shall be; 8mm Tri fold aluminium rivets measuring 27.7mm
long with a grip range of 1.0-9.5mm. Drill size 7.8-8.2mm.
⚠ Rivets installed in to the lap join of the roof sheet shall penetrate both joining roof
sheets.
Figure 8

After installation, the mandrel of the rivet shall visible below the sealing mound. The mandrel
is required to be in contact with the sealing mound to create a waterproof seal. In addition,
the seal of the rivet shall be compressed between the rail surface and the top of the rivet.
Figure 9
Seal Mandrel
Sealing Mound

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3.2.2 Clamps
For certain roof sheet profiles the X-Rail may be installed with the below clamps.
Figure 10
CLAMPS ROOF SHEET INSTALL TORQUE
(MAIN)
INSTALL TORQUE
(SIDE) IF APP
S5 Z KingZip400 40Nm 16Nm
3.3 Fasteners
All X-Rail Fasteners are M10 socket head cap screws. All fasteners shall be tightened to 40Nm
with a 6mm hex wrench.
⚠ All bolt threads must be applied with Loctite 243 thread-locker or equivalent prior to
assembly. (IMPORTANT NOTE: Before applying Loctite 243 use Loctite 7471 primer or
equivalent to activate the surface according to manufacturer’s instructions).
4 System Assembly
4.3.1 System Termination / Shuttle Stop
At the end of a system or at a point where it is necessary to prevent the passage of a shuttle,
a shuttle stop shall be installed. Drill an 11mm diameter hole in the centre of the rail, through
the top surface only. Where the rail terminates an end cap should be fitted.
Figure 11
1
2
STEP 1 STEP 2
COMPLETE SYSTEM TERMINATION AND STOP

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4.3.2 Rail Joins
Each join in the rail shall be fastened with the Rail Joiner as shown in Figure 12. Holes for rail
join fasteners to be made with drill bit XRAIL-TR-401 and drill fixture XRAIL-TR-402.
Figure 12
1
2
1
2
STEP 1 STEP 2
STEP 3 COMPLETE JOIN

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4.3.3 Corner Single Bend or Jogs
Single corners are used to change the direction of the rail without traversing a ridge.
Figure 13
1
2
2
1
STEP 1 STEP 2
2
1
STEP 3 STEP 4
2
1
STEP 5 STEP 6
COMPLETE SINGLE CORNER

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4.3.4 Corner Compound Bend
Compound corners are used to traverse a ridge. These corners are unique to specific
structures and may require further support not shown below. Please contact SafetyLink for
more information.
Figure 14
2
1
2
1
STEP 1 STEP 2
1
2
12
2
STEP 3 STEP 4
STEP 5 COMPLETE